Winding apparatus

ABSTRACT

A winder for webs of sheet material utilizes a pair of drive motors of different, although slightly overlapping, speed ranges for driving the cores upon which the webs are wound. The motor having the higher speed range is connected to one end of the core by an air clutch and the motor having the lower speed range is connected to the opposite end of the core by an overrunning clutch. The first motor, therefore, drives a core at a steadily decreasing speed and increasing torque as the overall diameter of the roll being built on the core increases. When this speed decreases to the upper speed limit of the second motor, the overrunning clutch engages and allows the drive to be transferred to the second motor. This permits the building of significantly larger rolls than would be feasible with a single drive motor.

[ 51 Jan. 18,1972

[ WINDING APPARATUS 3,207,452 9/1965 Haskin, Jr. et al.......................242/64 3,266,744 8/1966 Volm et a1.

[72] Inventors: Richard W. Phelps, Fulton; Ronald 0.

Meihofer, Baldwinsville, both of NY.

Primary Examiner-Stanley N. Gilreath Assistant ExaminerWerner H. Schroeder AttorneyMarechal, Biebel, French & Bugg [73] Assignee: The Black Clawson Company, Hamilton,

Ohio

ABSTRACT A winder for webs of sheet material utilizes a tors of different, although sl' [22] Filed: Sept. 8, 1969 PP NOJ pair of drive moightly overlapping, speed ranges for driving the cores upon which the webs are wound. Th

speed range is connected to one end utch and the motor having the lower d to the opposite end of the core by an overrunning clutch. The first motor, therefore, drives a core at a steadily decreasing speed and increasing torque as the overall diameter of the roll being built on the core increases.

eeek tmmw f S ow w nmm 86 m aTo S L N 0 u r tn 8 CD06 .I Pemh F P t 8 mmk .m m mo o w t W m 0 D .me l Snh a a m uo en w m ed t I. .wve o C ra 6 TC 6 enmfie l .l et nl. e r P rm Smt .E mOE h m .m t O S m .ma owmh m.n Wmdbw 52 m48 6W 42 @2 5 2222 4 n 2 s T n N m m n w A m .H P mm H C S lm s E nva e o e c T tmefl n A S S e nfne r T ho u S .1 .1 e D JTDB R E 0334 N 4566 U 9999 HUN 500 3 3224 3031 ,53 1813 l. 0472 6 H 2233 PATENTEB mu 8I972 3535415 INVENTOR RONALD O. M OFER a RICHARD W. ELPS WINDING APPARATUS BACKGROUND OF THE INVENTION In most manufacturing operations in which a continuous web is produced, it is desirable to provide winding mechanism for forming rolls of the material being produced by the process. In the paper industry, for example, not only are rolls formed as the* l,web is produced, but these rolls are usually unwound, processed in several ways, and rewound. With conventional winders the maximum diameter roll that can be built is severely limited by the speed range of the winder drive motors.

Thus, because it is desirable to wind the web at a constant linear speed, the angular speed imparted to the core upon which the web is wound must be steadily decreased as the diameter of the roll is increased. Additionally, in order to maintain constant web tension as the roll diameter increases, it is necessary that the torque exerted on the core be gradually increased. Since as a practical matter, the speed and torque range of a particular electric motor must be confined within moderate limits, the maximum diameter roll which may be formed is a function of the core or starting diameter and has been correspondingly limited.

Continuous winding requires that the web be transferred from the completed roll to a fresh core on the fly, and the angular speed of the fresh core must be sufficiently greater than that of the finished roll to maintain constant linear speed of the web. It is therefore common to provide a separate drive motor for each core, with the speeds of the respective motors being suitably controlled in accordance with maintained desired web tension, and subject to the speed and torque ranges of each such main drive motor. Prior art winders have also been provided with an auxiliary drive which is used only during roll changing, for the purpose of driving the fresh core at web speed while the web is transferred thereto and the main drive motor is accelerated sufficiently to take over the driving of the fresh core. A winder with such an auxiliary drive is shown in the patent to Kohler US. Pat. No. 2,586,832, wherein the new core is temporarily driven by a drive belt during roll change, but the capacity of the winder is still limited by the speed and torque ranges of main drive motor.

SUMMARY OF THE INVENTION The winder of the present invention utilizes a pair of motors for driving each core upon which the web of material is wound. Each of the motors has a different, although slightly overlapping, speed range with the motor having the lower speed range being capable of exerting greater torque to the winding roll than the motor having the higher speed range.

With this arrangement, the fresh core is driven by the highspeed, low-torque motor through means of an air clutch until the diameter of the reel being built has increased to a point where the rotative speed of the core has decreased to the lower limit of the speed range of the first motor. This lower limit of the speed range of the first motor is slightly less than the upper limit of the speed range of the second motor, and the second motor is connected to the opposite end of the core by an overrunning clutch. Therefore, when the rotative speed of the core reaches that of the upper limit of the second m0.-

tor, the drive is transferred from the first motor to the second.

motor.

After the drive has been transferred to the second motor, the first motor is disengaged from the core and reengaged with a fresh core, which it hen rotates at its upper speed limit. Thus when the roll being driven by the second motor is completed, the web may be transferred on the fly to the second, fresh core which has already been brought up to the proper rotative speed by the first motor.

By thus utilizing a pair of motors of conventional speed range, or even less, not only can appreciably larger rolls be built, but the necessity for auxiliary equipment for bringing the speed of a fresh core up to the web speed is eliminated. It should also be noted that the increase in the roll diameter permitted by the present invention is not merely cumulative. Thus if a pair of motors is used, each of which when used alone in a conventional system permits a roll build up to 6 to l, the result is not merely a buildup ratio of 12 to l, but rather, buildup of approximately 30 to 1.

Additionally, the use of two motors, each having a limited speed and torque range capability, is significantly less expensive than attempting to provide the same total speed and torque range with a single motor.

It will also be noted that, because each of the motors is operating in and around its optimum speed for a greater percentage of the time, the overall operation is more efficient and better tension control is obtained.

BRIEF DESCRIPTION OF THE DRAWING The single figure is a perspective view of apparatus constructed in accordance with the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT As seen in the drawing, a pair of supporting frames 10 and 1 1 are provided, joumaling a cross shaft 112 which is operatively associated with a source of power 13 for rotating the shaft 12. A pair of arms 20 and 21 are fixed to the shaft 12 and carry at their outer ends spindles 22, 23, 24 and 25. The spindles 22 and 23 are connected to sheaves 30 and 31 by means of air clutches 32 and 33, which may be of conventional construction. A belt 34 wraps the sheaves 30 and 31 and passes around a centrally located sheave 35 mounted on a collar 36 rotatively mounted on the shaft 12 by bearing means, not shown. Fixed to the opposite end of the collar 36 is an additional sheave 37 driven by the belt 38 wrapping the pulley 39, which in turn is driven by the motor 40.

The spindles 24 and 25 are operatively associated with a pair of sheaves 50 and 51 through a pair of clutches 52 and 53 which like the clutches 32 and 33, may be of the conventional air clutch type, and overrunning clutches 54 and 55 which may also be of conventional construction of the type shown, for example, in the above-noted patent to Kohler. A belt 56 wraps each of the pulleys 50 and 51 and engages a central pulley 57. The pulley 57 is mounted upon a collar 58 rotatably mounted on the shaft 12 by bearings, not shown, and an additional pulley 59 is mounted on the opposite end of the collar 58. A belt 60 wraps both the pulley 59 and a pulley 61 which is driven by the motor 62.

In operation, a core 70 is mounted between the spindles 22 and 25 and a web of material 71 attached thereto. The motor 40 has an upper speed limit equal to or greater than that necessary to rotate the core 70 at the proper speed to receive the web 71 under the desired amount of tension. In this connection, conventional speed control means will be utilized to correlate the speed of the motor 40, as well as the motor 62 when it is being used, to the desired web tension.

As the web 71 continues to be wound upon the core 70, and thus the diameter of the roll being built on the core 70 increases, the rotative speed of the core and hence of the motor 40 must be decreased while the torque exerted by the motor 430 is increased. Meanwhile, the motor 62 is running at its top speed but exerts no force on the core 70 since it is connected thereto by an overrunning clutch, and the speed imparted to the core 70 by the motor 40 during the first part of the operation is greater than the speed at which the overrunning clutch will cause the motor 62 to drive the core 70.

However, when the rotative speed of the core 70 finally decreases to a point where it matches the rotative speed imparted t0 the spindle 25 by the motor 62, drive motor 62 picks up the load from the motor 40 and drives the core until the desired roll diameter is reached. Ordinarily, transfer from one drive to the other will take place approximately halfway through the roll buildup, although it will be apparent that transfer could be at any selected point depending upon the speed and torque ranges of the motors selected.

After the motor 62 has assumed drive control, the air clutch engaging spindle 22 is disengaged. The clutches associated with spindles 23 and 24 are also disengaged and a new core placed thereon; after which these clutches are reengaged allowing the new core to be driven by driving force to the motor 40. Thus, when the roll being built on the core 70 is complete and the arms 20 and 21 are rotated to bring the new core supported on spindles 23 and 24 into position, the new core, because the motor 40 is operating under a substantially noload condition, rotates at a high rate of speed correlated to the linear speed of the web 71. Upon transfer of the winding operation from the core 70 to the new core, drive motor 62 is brought to rest, the completed roll built on the core 70 may be removed, a new core loaded into spindles 22 and 25 and the entire operation described above repeated.

While in the foregoing description the winding apparatus has been described as utilizing a pair of overrunning clutches 54 and 55 for driving the spindles 24 and 25, it will be apparent that the overrunning clutches may be dispensed with and the clutches 52 and 53 operated through suitable control mechanism, shown schematically at 75. With this arrangement, the control mechanism 75 would sense either the rotative speed of the core 70 or the diameter of the roll being built thereon and transfer the drive from the motor 40 to the motor 62 at the appropriate time by means of the clutches 52 and 53. Also, it will be apparent that the speed of the core 70 or the diameter of the roll being built on the core could be visually monitored and the engagement of the clutches 52 and 53 accomplished manually at the appropriate time. In all other respects, the operation of the system would be the same as that described above in conjunction with the overrunning clutches 54 and 55.

From the foregoing it will be apparent that the present invention greatly expands the maximum diameter roll that may be built with conventional motors, provides the initial highspeed rotation necessary for new roll cores, and at the same time permits more efficient utilization of the motors, whereby more precise control may be obtained.

As an example of the foregoing, if the motor 40 is selected to permit a 4 to 1 roll buildup ratio, it could easily handle a roll buildup of from to inches CD. If motor 62 were also selected to permit a 4 to 1 roll buildup, it would permit the 15- inch roll wound by motor 4-0 to be increased to 60-inches OD. The total buildup for the two motors, therefore, would not be merely twice the individual capacity of the two motors or 8 to l, but rather 5 to 60 inches or 12 to 1. Similarly, where a pair of motors which each permit a 6 to l buildup is used, the total possible buildup is not merely 12 to 1 but rather, 30 to 1.

While the form of apparatus herein described constitutes a preferred embodiment of the invention, it is to be understood that the invention is not limited to this precise form of apparatus, and that changes may be made therein without departing from the scope of the invention.

What is claimed is:

1. Apparatus of the type described comprising:

a. means for supporting a pair of cores in parallel spaced relationship to each other,

b. first means for rotatably driving one end of each of said cores through a first speed range,

c. second means for rotatably driving the opposite end of each of said cores through a second speed range d. the lower limit of said first speed range being higher than the upper limit of said second speed range, and

e. means for transferring drive of said core from said first driving means to said second driving means when the speed of said core falls between said upper and lower limits.

2. The apparatus of claim 1 wherein:

a. said transferring means comprises an overrunning clutch.

3. The apparatus of claim 1 wherein:

a. said transferring means comprises control means for shifting driving of said cores from said first named driving means to said second named driving means.

4. The apparatus of claim 2 further comprising:

a. means for selectively engaging and disengaging said first driving means from said one end, and

b. means for selectively engaging and disengaging said second driving means from said opposite end.

5. The apparatus of claim 4 wherein:

a. said engaging and disengaging means comprise air clutches.

. The apparatus of claim 1 wherein:

. said first driving means is of lower torque capacity than said opposite end driving means.

7. Apparatus of the type described comprising:

. a pair of spindle support arms,

. means rotatably supporting said spindle support arms in spaced, aligned relationship to each other,

c. a rotatable spindle mounted in each end of each of said arms,

d. a first relatively high-speed, low-torque motor rotatable through a first speed range,

e. an air clutch associated with each of the spindles in one of said arms and said first motor,

f. a second, relatively low-speed, high-torque motor rotatable through a second speed range,

g. an overrunning clutch engageable with each of the spindles in the other of said arms and said second motor when the speed of said other arm spindles decrease to the upper limit of said second speed range, and

h. an air clutch associated with each of the spindles in said other of said arms and said second motor.

. Apparatus of the type described comprising:

a. means for supporting a pair of cores in parallel spaced relationship to each other,

b. means for rotatably driving one end of each of said cores through a first speed range,

c. means for rotatably driving the opposite end of each of said cores through a second speed range,

d. overrunning clutch means for automatically engaging said opposite end driving means with either of said opposite ends of one of said cores while said core is rotating when the speed of said core decreases to the upper limit of said second speed range,

. means for selectively engaging and disengaging said one end driving means from said one end, and

f. means for selectively engaging and disengaging said opposite end driving means from said opposite end.

9. Apparatus of the type described comprising:

a. means for supporting a pair of cores in parallel spaced relationship to each other,

b. means for rotatably driving one end of each of said cores through a first speed range,

c. means for rotatably driving the opposite end of each of said cores through a second speed range,

(I. means for automatically engaging said opposite end driving means with either of said opposite ends of one of said cores while said core is rotating when the speed of said core decreases to the upper limit of said second speed range,

e. said automatic engaging means comprising control means for shifting driving of said cores from said first named driving means to said second named driving means,

f. means for selectively engaging and disengaging said one end driving means from said one end, and

g. means for selectively engaging and disengaging said opposite end driving means from said opposite end.

10. The apparatus of claim 9 wherein:

a. said engaging and disengaging means comprise air clutches.

11. Apparatus of the type described comprising:

a. means for rotatably supporting a core,

b. first means for driving said core through a first speed range,

c. second means for driving said core through a second speed range,

d. the lower limit of said first speed range being higher than the upper limit of said second speed range, and

a. means for selectively engaging and disengaging said first driving means from said core, and

b. means for selectively engaging and disengaging said second driving means from said core.

15. The apparatus of claim 14 wherein:

a. said engaging and disengaging means comprise air clutches.

16. The apparatus of claim 11 wherein:

a. said first driving means is of lower torque capacity than said opposite end driving means. 

1. Apparatus of the type described comprising: a. means for supporting a pair of cores in parallel spaced relationship to each other, b. first means for rotatably driving one end of each of said cores through a first speed range, c. second means for rotatably driving the opposite end of each of said cores through a second speed range d. the lower limit of said first speed range being higher than the upper limit of said second speed range, and e. means for transferring drive of said core from said first driving means to said second driving means when the speed of said core falls between said upper and lower limits.
 2. The apparatus of claim 1 wherein: a. said transferring means comprises an overrunning clutch.
 3. The apparatus of claim 1 wherein: a. said transferring means comprises control means for shifting driving of said cores from said first named driving means to said second named driving means.
 4. The apparatus of claim 2 further comprising: a. means for selectively engaging and disengaging said first driving means from said one end, and b. means for selectively engaging and disengaging said second driving means from said opposite end.
 5. The apparatus of claim 4 wherein: a. said engaging and disengaging means comprise air clutches.
 6. The apparatus of claim 1 wherein: a. said first driving means is of lower torque capacity than said opposite end driving means.
 7. Apparatus of the type described comprising: a. a pair of spindle support arms, b. means rotatably supporting said spindle support arms in spaced, aligned relationship to each other, c. a rotatable spindle mounted in each end of each of said arms, d. a first relatively high-speed, low-torque motor rotatable through a first speed range, e. an air clutch associated with each of the spindles in one of said arms and said first motor, f. a second, relatively low-speed, high-torque motor rotatable through a second speed range, g. an overrunning clutch engageable with each of the spindles in the other of said arms and said second motor when the speed of said other arm spindles decrease to the upper limit of said second speed range, and h. an air clutch associated with each of the spindles in said other of said arms and said second motor.
 8. Apparatus of the type described comprising: a. means for supporting a pair of cores in parallel spaced relationship to each other, b. means for rotatably driving one end of each of said cores through a first speed range, c. means for rotatably driving the opposite end of each of said cores through a second speed range, d. overrunning clutch means for automatically engaging said opposite end driving means with either of said opposite ends of one of said cores while said core is rotating when the speed of said core decreases to the upper limit of said second speed range, e. means for selectively engaging and disengaging said one end driving means from said one end, and f. means for selectively engaging and disengaging said opposite end driving means from said opposite end.
 9. Apparatus of the type described comprising: a. means for supporting a pair of cores in parallel spaced relationship to each other, b. means for rotatably driving one end of each of said cores through a first speed range, c. means for rotatably driving the opposite end of each of said cores through a second speed range, d. means for automatically engaging said opposite end driving means with either of said opposite ends of one of said cores while said core is rotating when the speed of said core decreases to the upper limit of said second speed range, e. said automatic engaging means comprising control means for shifting driving of said cores from said first named driving means to said second named driving means, f. means for selectively engaging and disengaging said one end driving means from said one end, and g. means for selectively engaging and disengaging said opposite end driving means from said opposite end.
 10. The apparatus of claim 9 wherein: a. said engaging and disengaging means comprise air clutches.
 11. Apparatus of the type described comprising: a. means for rotatably supporting a core, b. first means for driving said core through a first speed range, c. second means for driving said core through a second speed range, d. the lower limit of said first speed range being higher than the upper limit of said second speed range, and e. means for transferring drive of said core from said first driving means to said second driving means when the speed of said core falls between said lower and upper limits.
 12. The apparatus of claim 11 wherein: a. said transferring means comprises an overrunning clutch.
 13. The apparatus of claim 11 wherein: a. said transferring means comprises control means for shifting driving of said cores from said first named driving means to said second named driving means.
 14. The apparatus of claim 12 further comprising: a. means for selectively engaging and disengaging said first driving means from said core, and b. means for selectively engaging and disengaging said second driving means from said core.
 15. The apparatus of claim 14 wherein: a. said engaging and disengaging means comprise air clutches.
 16. The apparatus of claim 11 wherein: a. said first driving means is of lower torque capacity than said opposite end driving means. 